Pre-proof temperature controlling assembly

ABSTRACT

The present invention relates to a pre-proof temperature controlling assembly associated with an off-press apparatus for laminating an image sheet to an image receiving substrate and, more particularly, for laminating a plurality of image sheets to the receiving substrate and then laminating a portion of the receiving substrate to a display sheet.

This is a continuation of application Ser. No. 08/110,458 filed Aug. 23,1993, now abandoned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a pre-proof temperature controlling assemblyassociated with an off-press apparatus for laminating an image sheet toan image receiving substrate and, more particularly, for laminating aplurality of image sheets to the receiving substrate and then laminatinga portion of the receiving substrate to a display sheet.

2. Description of Related Art

Reproduction of color images through printing is an involved processrequiring a breakdown of an original image into a number of fundamentalsingle color images and the eventual recombination of the single colorimages through multiple printings into a full color reproduction of theoriginal. Color image reproduction typically includes the followingsteps.

First, using filtering and other photographic techniques a number ofcolor separation transparencies or color separations are produced,typically four, each bearing a halftone dot and/or a continuous tone(contone) image corresponding, for instance, to magenta, cyan, yellowand black portions of the original. Second, a printing plate is made foreach color separation by exposing a sensitized plate through one of thetransparencies and developing the plate. Third, the printing plates aremounted on a multistage printing press which prints inks on a substrate,typically paper, sequentially and in register, one on top of another,four halftone and/or contone images corresponding to each of the colorseparations to create a full color reproduction of the original.

In the case of halftone images, the various colors are reproduced by thesuperposition of a multiplicity of dots of varying diameters and colorscorresponding to the four color separations. Any deviation in the sizeor position of the printed dots results in color shifts in the finalprinted image. As a result of this reproduction process, setting up thepress and printing a four color image is economically feasible typicallyonly when employed for printing large quantities of a given original.

It is desirable to be able to predict the final image appearance beforeit is printed, and preferably before making printing plates by reviewingimages made directly from the color separation transparencies. The artof evaluating the color separation transparencies and deciding whetherthe various colors have indeed been properly separated is calledproofing. Proofing is a process which uses the color separations tocreate a colored image called a proof to visualize what the finalprinted image will look like typically without actually making printingplates and running the printing press. Proofing through the creation ofproofs shows the printer and customer what the job will look like afterprinting, so changes can be made, if necessary, to the color separationsbefore the job goes to press where it can waste expensive press time,paper and ink if it is not right. Proofs are used for many purposesincluding for customer approval, for checking compatibility of a numberof subjects to be printed on the same plate or job, for internal qualitychecking and control, and for relatively small numbers of finalreproductions.

For many years the only way to make proofs was to print them on a press.This involved making plates, mounting them on the press, making thepress ready to run, and running a few prints. Proofs of this type arevery expensive because they involve labor intensive operations and theuse of expensive materials (e.g., plates) and cost intensive equipment(e.g., the press). Special proof presses have been built to eliminatethe high costs of using production presses, but manpower costs are stillhigh and special proof presses do not always reproduce the printing andvisual characteristics of the production press. Furthermore, pressproofing by either of these techniques takes a long time to make proofs.

Because of the time and expense to make press proofs attempts have beenmade to develop and use less expensive and faster alternatives to pressproofs. These are usually made by photochemical or photomechanical meansand are referred to as off-press, pre-press or pre-plate proofs.

Photochemical or photomechanical proofing systems typically usephotosensitive elements in making proofs. These systems generally makeproofs by exposing photosensitive elements to actinic radiation throughone of the image bearing color separation transparencies to produce aduplicate image that is either a positive or a negative of thetransparency depending on the element used. The radiation may makesoluble areas insoluble, insoluble areas soluble, tacky areas nontacky,or nontacky areas tacky depending on the element used. After imagewiseexposure, the photosensitive element can be developed by washing outsoluble areas. Then tacky areas of the element may have to be toned witha dry or liquid colorant. This process is repeated for all colorseparations. Then the processed elements are laminated together one at atime sometimes on a support or substrate. Protective layers may bepeeled apart and removed from the elements before they are laminated tothe support or other image elements. Finally, the four color images maybe transferred from the support to a receptor, transfer or displaysheet, such as a sheet of paper, to form the final proof.

Many photosensitive elements used for image reproduction have thedisadvantage that they must be washed out by an organic solvent oraqueous base. For instance, U.S. Pat. No. 4,053,313 to Fan discloses aphotosensitive element comprising a solvent-processable photosensitivelayer, a tonable elastomeric layer and a support, that is processed(i.e., washed-out) by a mixture of water and organic solvent. Theelements disclosed in U.S. Pat. Nos. 4,376,158 and 4,376,159 to Specklerrequire aqueous base for washout. Precolored diazo based photosensitiveelements which are developed in a mixture of 1-propanol and water aredisclosed, for example, in U.S. Pat. No. 3,671,236 to Van Beusekom, U.S.Pat. No. 4,656,114 to Cederburg and U.S. Pat. No. 4,666,817 to Sachi.Use of organic solvents or aqueous bases frequently is undesirable dueto flammability, toxicity, corrosion and/or waste disposalconsiderations. The photosensitive elements disclosed in these Fan andSpeckler patents also require the developed (i.e., washed-out) elementsto be toned either manually or in a toning apparatus.

Photosensitive elements are known and are being developed that do nothave the above described disadvantages. Specifically, U.K. Patentpublication GB 2144867 B discloses photosensitive elements havingentirely aqueously developable precolored layers containing a coloranton a removable support. The U.K. patent further describes aphotomechanical process for forming a multicolor image, suitable for useas an off-press proof utilizing the aqueously developable photosensitiveelements. The process for preparing a multicolor image is accomplishedby (1) imagewise exposure of a first one of the precoloredphotosensitive elements comprising an aqueously developable precoloredphotosensitive layer on a removable support through a first one of thecolor separation transparencies forming image areas and non-image areasin its aqueously developable precolored layer, (2) processing theexposed element to develop the color image by washing away the non-imageareas with water, (3) laminating the image bearing element to asubstrate, and then (4) peeling the removable support from the imagebearing element. A second color image element is made by exposing asecond precolored photosensitive element with a second one of the colorseparation transparencies, processing to develop the color image,laminating in register the second color image element to the first colorimage element on the substrate and peeling the removable support fromthe second color image element. By repeating the exposing, processing,laminating in register, and peeling steps two more times, a four colorimage can be obtained. As long as the emulsion layer of the colorseparation contacts the photosensitive layer in the photosensitiveelement during the exposure step as is preferred, the process describedin this U.K. patent results in a wrong reading proof on the substrate.This means that the image on the substrate is a mirror image of thatcaptured in the color separations.

Often it is desirable to view the multicolored image on a receptor or atransfer sheet, such as paper, which is the same as or similar to thatwhich will be used in the final printing run. In this case, themulticolor image is transferred to the desired receptor by laminatingand then peeling away the substrate. This results in a right readingproof assuming the emulsion layer of the color separation contacts thephotosensitive layer in the photosensitive element during the exposurestep. A right reading proof is the same as the original image, not amirror image.

Many apparatuses have been developed for laminating photosensitiveelements. Different laminating apparatuses are designed and used forlaminating different photosensitive elements. However, aqueouslydevelopable precolored photosensitive elements are a relatively recentdevelopment. As such, few apparatuses exist for use in laminatingaqueously developed precolored photosensitive elements or image sheetsto supports or receiving substrates.

U.S. Pat. No. 4,659,927 to Tago et al. assigned to Fuji Photo Film Co.,Ltd., discloses a laminator and a method utilizing the laminator forpreparing a multicolor proof on a support plate of good thermalconductivity. The laminator comprises a pair of insertion rollers forfeeding superposed sheets on the support plate into the laminator, apair of heated rollers for receiving the sheets and plate from theinsertion rollers and for heating and applying pressure to the sheetsand plate, and a pair of cooling rollers for cooling the sheets andplate fed from the heated rollers.

A laminator is commercially available from Fuji Photo Film Co., Ltd.,for laminating aqueously developed precolored photosensitive elements orimage sheets to supports or receiving substrates. The laminator includesthe parts described in the aforedescribed Fuji patent. The laminatoroperates at one nip distance and pressure setting limiting its use witha variety of photosensitive elements, supports or receiving substratesand final transfer or display sheets. Only one of the heated rollers isdriven by a motor. The other heated roller is rotated by frictionalcontact through the sheets sandwiched between the rollers. This causesslippage of the layers in the sheets during the laminating causingmisregistration of colors in reproduced images and transferirregularities.

U.S. Pat. No. 5,075,722 and U.S. patent application Ser. No. 07/612,975disclose an off-press apparatus for laminating aqueously developedprecolored photosensitive elements or image sheets to supports orreceiving substrates using a carrier plate in the process. Thislaminator operates at more than one operating pressure or linear forcesetting enabling its use with a variety of photosensitive elements,supports or receiving substrates and final transfer or display sheets.This laminator includes means for driving a first roller assembly and asecond roller assembly such that the magnitude of the tangentialvelocity of a point on the circumference of the first roller assembly isthe same as the magnitude of the tangential velocity of a point on thecircumference of the second roller assembly. This reduces slippage ofthe layers in the sheets during the laminating.

A difficulty associated with laminate-in-register systems, such as thosedisclosed in U.S. Pat. Nos. 5,075,722 and 4,659,927, is in laminating aprocessed color image element to the receiving substrate without causingany image distortion. Image distortion can be seen when dots of a colorimage of subsequent color laminations do not lay in proper position todots of a previous layer color image. The mis-alignment ormis-registration of the dots of each color image element is referred toas registration error. Registration error becomes noticeable as a colorshift when dots are mis-registered by more than half the diameter of thetypical sized dot. In commercial 200 lines per inch printing, thismaximum registration error would translate to about 3 microns.

A need exists to provide a method and apparatus for laminating a colorimage sheet to an image receiving substrate with improved registrationof resulting proofs. Particularly, this need exists in off-pressapparatus for laminating aqueously developed precolored photosensitiveelements or image sheets to supports or receiving substrates using acarrier plate in the process.

SUMMARY OF THE INVENTION

The invention relates to an improvement in an off-press apparatus forlaminating an image sheet to an image receiving substrate supported on acarrier plate, the apparatus comprising:

a laminator comprising:

a support frame having a right frame and a left frame;

a first lamination roller assembly rotatably mounted between the rightframe and the left frame;

a second lamination roller assembly rotatably mounted between the rightframe and the left frame parallel or substantially parallel to the firstroller assembly forming a nip between the roller assemblies;

means for rotating the first roller assembly and/or the second rollerassembly;

means for heating the first lamination roller assembly and the secondlamination roller assembly to about a first temperature; and

a housing for substantially enclosing the first lamination rollerassembly, the second lamination roller assembly, and the heating means,the housing having a housing inlet and a housing outlet, the housingretaining heat generated by the heating means within the housinggenerally at a second temperature below the first temperature;

a sheet preparation and feed table having an end mounted to thelaminator adjacent the housing inlet; and

a sheet output receiving table having an end mounted to the laminatoradjacent the housing outlet; the improvement comprising:

a pre-proof temperature controlling assembly comprising:

a tray with a top surface and a bottom surface, the top surfaceextending from the housing inlet to about the nip such that when animage sheet is placed or stacked on an image receiving substrate on acarrier plate on the table and the stacked sheet, substrate and carrierplate are slid along the table into the housing inlet along the topsurface of the tray into the nip between the first roller assembly andthe second roller assembly, the roller assemblies will transport thestacked sheet, substrate and carrier plate between the rollerassemblies, laminate the sheet and substrate together and transport thelaminated sheet and substrate and the carrier plate out the housingoutlet onto the sheet output receiving table; and

means for controlling the temperature of the stacked sheet, substrateand carrier plate on the tray at about a third temperature above roomtemperature and below the second temperature while the stacked sheet,substrate and carrier plate are being fed to and then transportedbetween the roller assemblies.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be more fully understood from the following detaileddescription thereof in connection with accompanying drawings describedas follows.

FIG. 1 is a perspective view of a first embodiment of a pre-prooftemperature controlling assembly in an off-press apparatus forlaminating an image sheet to an image receiving substrate supported on acarrier plate in accordance with the present invention.

FIG. 2 is a perspective view of the pre-proof temperature controllingassembly and part of a laminator included in the off-press apparatus ofFIG. 1 with housing panels shown in phantom line to show internal parts.

FIG. 3 is a schematic illustration of the pre-proof temperaturecontrolling assembly in the off-press apparatus of FIG. 1.

FIG. 4 is a perspective view of the pre-proof temperature controllingassembly with parts exploded from one another.

FIG. 5 is a perspective view of a manifold in accordance with thepresent invention with parts exploded from one another.

FIG. 6 is a cross sectional view generally along a first plane through afirst duct network and a third chamber of the manifold.

FIG. 7 is a cross sectional view generally along a second plane parallelto the first plane and bisecting the third chamber and a 2nd third ductnetwork of the manifold.

FIG. 8 is a cross section view of a heat sink extending from a bottomsurface of a tray of the pre-proof temperature controlling assembly.

FIG. 9 is a perspective view of the pre-proof temperature controllingassembly of FIG. 1 with roller assemblies exploded away from theapparatus.

FIG. 10 is a schematic illustration of an electrical control system forthe present invention.

FIG. 11 is a perspective view of a second embodiment of a pre-prooftemperature controlling assembly with parts exploded from one another.

FIG. 12 is a cross sectional view generally along a first plane throughthe pre-proof temperature controlling assembly of FIG. 11.

FIG. 13 is a perspective view of a flapper mechanism for directing airflow in the pre-proof temperature controlling assembly of FIG. 11.

FIG. 14 is a schematic illustration of laminating by applying pressureand heat through a nip between a first roller assembly and a secondroller assembly to sandwich an image sheet having one colored imagetogether with a receiving substrate having no colored images.

FIG. 15 is a schematic illustration of laminating by applying pressureand heat through a nip between a first roller assembly and a secondroller assembly to sandwich the receiving substrate having one coloredimage together with a transfer sheet.

FIGS. 16-18 are schematic illustrations of intermediate laminating stepsin a process of forming a multicolor proof.

FIG. 19 is a schematic illustration of laminating by applying pressureand heat through a nip between a first roller assembly and a secondroller assembly to sandwich the receiving substrate having four coloredimages together with a transfer sheet.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

A substantial contributor to registration error is from the dimensionalinstability of a polyester base used in each of the color image elementsand the receiving substrate. Inherently the polyester base changesdimensions, i.e., expands, when heated, but eventually returns close toits original dimensions when returned to room temperature. Since duringlamination, the color image of the color image element transfers fromthe element to the receiving substrate, the position of the dots of thecolor image, i.e., registration, is influenced by the dimensionalchanges that occurs for each base.

The dimensional stability of the color image elements and the receivingsubstrate is influenced by the thermal energy, i.e., heat, applied tothe lamination stack, i.e., the color image element and receivingsubstrate. If the applied thermal energy experienced by the laminationstack is not uniform, the dimensional instabilities of the element andthe substrate cause distortion of the image which results inregistration error in a proof. Prior to the present invention,non-uniformities in the lamination process have been mitigated primarilyby assuring that temperature and pressure profiles of the nip rollers inthe laminator are constant.

However, the use of a carrier plate in an off-press laminating apparatusintroduces a non-uniformity to the thermal energy applied to thelamination stack during lamination. As the lamination stack passesthrough heated nip rollers in the laminator, heat wicks up, i.e.,travels, the carrier plate and preheats the lamination stack. The heatwicking results in the trailing portion of the lamination stackexperiencing the applied thermal energy for a longer period of time thanthe leading portion of the lamination stack. This phenomena causes anever increasing applied thermal energy down the length of the laminationstack.

It has been discovered that a pre-proof temperature controlling assembly8 (FIG. 1) in accordance with the present invention effectively preventsheat wicking up the carrier plate and maintains the uniformity of theapplied thermal energy to all locations on the lamination stack. Theresult is a reduction in the dimensional changes of the color imageelements and receiving substrate which in turn improves registration ofthe proof.

Referring to FIG. 1, there is illustrated a perspective view of thepre-proof temperature controlling assembly 8 in an off-press laminatingapparatus 10 for laminating an image sheet to an image receivingsubstrate supported on a carrier plate in accordance with the presentinvention. The term "off-press" is meant to be equivalent to the termspre-press and pre-plate. The off-press laminating apparatus 10 generallycomprises a laminator 12, a sheet preparation and feed table 14 and asheet output receiving table 16.

The laminator 12 comprises a front side 20, a rear side 22, a left side24 and a right side 26. An operator control pad 18 is convenientlylocated on the laminator 12. FIG. 2 is perspective view showing thepre-proof temperature controlling assembly 8 and part of the laminator12 with housing panels 28 shown in phantom lines to show internal parts.FIG. 3 is a schematic illustration of an image sheet 30 on an imagereceiving substrate 32 supported on a carrier plate 34 partially on thepre-proof temperature controlling assembly 8 in the off-press apparatus10.

As best seen in FIG. 2, the laminator 12 comprises a support framehaving a right frame 36 and a left frame 38. The laminator 12 furtherincludes a first lamination roller assembly 40 and a second laminationroller assembly 42. The first lamination roller assembly 40 is rotatablymounted between the right frame 36 and the left frame 38. The secondlamination roller assembly 42 is rotatably mounted between the rightframe 36 and the left frame 38 parallel or substantially parallel to thefirst roller assembly 40 forming a nip 44 between the roller assemblies40,42. See FIG. 3. The laminator 12 further includes means 46 forrotating the first roller assembly 40 and the second roller assembly 42.The rotating means 46 can include gears and chains driven by a motorassembly possibly through the use of a gear box. The laminator 12further includes means 48,50 for heating the first lamination rollerassembly 40 and the second lamination roller assembly 42 to about afirst temperature T1. The heating means 48,50 can comprise heaters orheater elements positioned in the first and second roller assemblies40,42. A housing 52 substantially encloses the support frame 36,38, thefirst lamination roller assembly 40, the second lamination rollerassembly 42, and the heating means 48,50. The housing 52 can comprise aplurality of housing panels 27,28,29. Referring to FIG. 3, the housing52 has a housing inlet 54 and a housing outlet 56. The housing 52 servesto retain the heat generated by the heating elements 48,50 such that theair temperature within the housing 52 when the laminator 12 is operatingis at a second temperature T2.

Referring to FIGS. 1 and 3, the sheet preparation and feed table 14 hasa first end mounted to the laminator 12 adjacent the housing inlet 54.The table 14 extends from the front side 20 of the laminator 12 and issupported at a second end remote from the laminator 12 by legs or asupport assembly 58. The sheet output receiving table 16 has a first endmounted to the laminator 12 adjacent the housing outlet 56. The table 16extends from the rear side 22 of the laminator 12 and is supported at asecond end remote from the laminator 12 by legs or a support assembly60.

FIG. 4 is a perspective view of the pre-proof temperature controllingassembly 8 with parts exploded from one another. The pre-prooftemperature controlling assembly 8 comprises a tray 62 with a topsurface 64 and a bottom surface 66. Referring back to FIGS. 2 and 3, thetop surface 64 extends from the housing inlet 54 to about the nip 44such that when an image sheet 30 is placed or stacked on an imagereceiving substrate 32 on a carrier plate 34 on the table 14 and thestacked sheet 30, substrate 32 and carrier plate 34 are slid along thetable 14 into the housing inlet 54 along the top surface 64 of the tray62 into the nip 44 between the first roller assembly 40 and the secondroller assembly 42, the roller assemblies 40,42 will transport thestacked sheet 30, substrate 32 and carrier plate 34 between the rollerassemblies 40,42, laminate the sheet 30 and substrate 32 together andtransport the laminated sheet 30 and substrate 32 and the carrier plate34 out the housing outlet 56 onto the sheet output receiving table 16.

Referring to FIGS. 4 and 5, the pre-proof temperature controllingassembly 8 further comprises means 68 for controlling the temperature ofthe stacked sheet 30, substrate 32 and carrier plate 34 on the tray 62at about a third temperature T3 above room temperature and below thesecond temperature while the stacked sheet 30, substrate 32 and carrierplate 34 are being fed to and then transported between the rollerassemblies 40,42. Preferably, the temperature controlling means 68comprises a first air blower 70, a second air blower 72, a manifold 74and an electrical control system 76.

FIG. 6 is a cross sectional view generally along a first plane throughthe manifold 74. FIG. 7 is a cross sectional view through the manifold74 generally along a second plane parallel to the first plane.

Referring to FIG. 6, the first air blower 70 can have a first bloweroutlet 76 and a first blower inlet 78 positioned to receive air at abouta fourth 10 temperature T4 below the third temperature from outside thehousing 52. (See FIG. 3.) The second air blower 72 can have a secondblower outlet 80 and a second blower inlet 82 positioned to receive airat about the second temperature T2 from inside the housing 52. (Againsee FIG. 3.)

Referring to FIGS. 5 and 6, the manifold 74 can comprise a first ductnetwork or duct 90, a second duct network or duct 92 and a plurality ofthird duct networks or ducts 94A-D. The first duct 90 has a first inlet96, a second inlet 98 and a plurality of outlets 100A-D. The first ductfirst inlet 96 is connected to the first blower outlet 76. The firstduct second inlet 98 is connected to the second blower outlet 80. Thesecond duct 92 and the bottom surface 66 of the tray 62 define aplurality of chambers 102A-D. There can be any number of chambers 102.The embodiment illustrated in the Figures has a first chamber 102A, asecond chamber 102B, a third chamber 102C, and a fourth chamber 102D.Each of the chambers 102A-D has an inlet 104A-D and an outlet 106A-D.One of the chamber inlets 104A-D is connected to each one of theplurality of first duct outlets 100A-D such that air blown through thechambers 102A-D cools or heats the tray 62. Each one of the third ducts94A-D has an inlet 108A-D and an outlet 110A-D. One of the third ductinlets 108A-D is connected to each one of the chamber outlets 106A-D. Ifthere are four chamber outlets 106A-D as illustrated in the Figures,there are four third ducts, i.e., a 1st third duct 94A, a 2nd third duct94B, a 3rd third duct 94C and a 4th third duct 94D. The third ductoutlets 110A-D are positioned to exhaust air to the environment outsideof the housing 52. (See FIG. 3.)

Referring to FIGS. 4 and 6, the temperature controlling means 68preferably further comprises means 112 in the manifold 74 for directingair from the first blower outlet 76 away from the second blower outlet80 and for directing air from the second blower outlet 80 away from thefirst blower outlet 76. Preferably, the directing means 112 is a flappervalve comprising a light weight flat door 114 connected by a hinge 116in the first duct 90 adjacent the first duct first inlet 96 and thefirst duct second inlet 98. When air is blown into the first duct firstinlet 96 and air is not blown into the first duct second inlet 98, theflapper valve 112 is blown away from the first duct first inlet 96 andtowards, thereby closing or blocking, the first duct second inlet 98.This directs the air out the first duct outlets 100A-D, rather thanallowing the air to escape through the first duct second inlet 98. Whenair is blown into the first duct second inlet 98 and air is not blowninto the first duct first inlet 96, the flapper valve 112 is blown awayfrom the first duct second inlet 98 and towards, thereby closing orblocking, the first duct first inlet 96. Again this directs the air outthe first duct outlets 100A-D, rather than allowing the air to escapethrough the first duct first inlet 96. When air is blown into the firstduct first inlet 96 and air is simultaneously blown into the first ductsecond inlet 98, the flapper valve 112 is forced to an intermediateposition allowing air to be blown in from both the first duct firstinlet 96 and the first duct second inlet 98.

Referring to FIGS. 4, 6, 7 and 8, the tray 62 includes at least onethermally conductive heat sink 118 extending from the bottom surface 66of the tray 62 into the manifold 74. Each heat sink 118 has ribs or fins120 projecting into one of the chambers 102A-D. Preferably, the fins 120extend longitudinally in the direction of air flow through the chambers102A-D. The tray 62 and heat sinks 118 can be aluminum and cast orotherwise formed as one unit. Alternatively, as shown in the Figures,the tray 62 can be made of an aluminum plate 122 with a hard, smoothtetrafluoroethylene coating 124. Threaded studs 126 can be fixed to andextend from the bottom surface of the aluminum plate 122 which receivenuts 127 to secure individual aluminum heat sinks 118 to the bottomsurface 66 of the tray 62 so as one of the heat sinks 118 extends intoeach one of the chambers 102A-D. A thin thermally conductive putty layer128 can be applied between the tray 62 and the heat sinks 118 toincrease the thermal conductivity between them.

Referring to FIG. 9, preferably, the temperature controlling means 68further comprises a pair of roller supports 130 supporting a pluralityof non-lamination roller assemblies 132. One of the roller supports 130can be mounted on each side of the tray 62 transverse to the directionof feeding a stacked sheet 30, substrate 32 and carrier plate 34 to thenip 44. Each support 130 can have a plurality of bearing retaining slots134. Each one of the non-lamination roller assemblies 132 can have aroller, shafts and bearings. The rollers can extend above and transverseto the tray 62. The shafts can extend out ends of the rollers. Thebearings can be rotatably supported on the shafts and retained in thebearing retaining slots 134. When the stacked sheet 30, substrate 32 andcarrier plate 34 are slid along the top surface 64 of the tray 62towards the nip 44, the non-lamination roller assemblies 132 apply aslight force on the stacked sheet 30, substrate 32 and carrier plate 34maintaining the carrier plate 34 in contact with the tray 62. Thisincreases and ensures good thermal conductivity between the tray 62 andthe carrier plate 34.

The electrical control system 76 can comprise means for controlling theoperation of the first blower 70 and the second blower 72 to maintainthe temperature of the tray 62 substantially at the third temperature.Preferably, the first temperature is about 100° C. (i.e., degreesCelsius), the second temperature is about 40°-45° C., the thirdtemperature is about 35° C., and the fourth temperature is about 25° C..This effectively cools the temperature of the tray 62. In a firstembodiment, the electrical control system 76 operates the first blower70 and the second blower 72 alternately at constant flow rates tomaintain the temperature of the tray 62 substantially at the thirdtemperature. In a second embodiment, both blowers can have variable flowrates. In a third embodiment, one of the blowers can be constantlyblowing at a constant flow rate and the other blower can be turned onand off at a constant flow rate to control the temperature of the tray62.

FIG. 10 is a schematic illustration of the first embodiment of theelectrical control system 76 for the pre-proof temperature controllingassembly 8 of the present invention. The electrical control systemincludes a programmable logic controller (PLC) 230 connected to a powerdistribution network 232 or the like through a step down transformer 234which converts voltage, such as, from 220 Volts to 115 Volts at 50Watts. A suitable PLC 230 that can be used in the present invention iscommercially available under model number D100CR14 from Cutler Hammerwith offices in Philadelphia, Pa. The suitable power distributionnetwork 232 may include fuse blocks, terminal blocks andinterconnections between components of the control system. For instance,the power distribution network 232 may be connectable by an input cable236 to a power supply, such as a 220 Volt 16 Amp AC power supply (notdepicted). Alternatively, the control system 76 could be designed toreceive power from a 120 Volt AC power supply in which case the stepdown transformer 234 would not be needed.

The key pad 18 is connected by lines 262,264 to provide and receivesignals from the PLC 230. A DC power supply 238 is connected between theinput cable 236 and the control or key pad 18. The DC power supply 238continuously provides DC power to all soft-on/soft-off power circuits inthe control system 76. A power switching device 256 is connected by aline 255 between the control or key pad 18 and the power distributionnetwork 232. A suitable power switching device 256 that can be used inthe present invention is commercially available under model numberCE15DN2B from Cutler Hammer. The power switching device 256 is asoft-on/soft-off circuit having several relays and a large contactor tohandle the power. The soft-on/soft-off circuit 256 provides DC power toitems connected to the DC power supply 238. A line 258 alsointerconnects the power switching device 256 with an input to the PLC230.

The electrical control system 76 includes an electrical temperaturecontrol subsystem 290. The electrical temperature control subsystem 290comprises a temperature controller 292 connected to a first line 294which in turn is connected to the power distribution network 232. Thefirst blower 70 and the second blower are connected in lines 296 and298, respectively, in parallel between the temperature controller 292and a line 300 which in turn is connected to the power distributionnetwork 232. A temperature sensor or thermocouple 302 is positioned tosense the temperature of the tray 62 and is connected to provide signalsrepresentative of the sensed temperature to the temperature controller292. Suitable temperature controllers 292 that can be used in thepresent invention are commercially available under model numberPYZ4TDY1-IV from Fuji Electric of Japan. The temperature controller 292includes an alarm circuit 306. The alarm circuit 306 is connected inseries between the DC power supply 238 and the PLC 230.

In operation, the apparatus 10 is activated by pressing a "power on/off"toggle switch 252 which sends a signal to the device 256 over line 255.Then the device 256 applies power to the entire control system 76.

The temperature controller 292 also switches on in response to pressingthe "power on" switch 252. The temperature controller 292 controls thetemperature of the tray 62 based on manually inputted preset values andfeedback from the temperature sensor 302.

A high temperature preset and a low temperature preset can be inputtedto the alarm circuit 306. The alarm circuit 306 monitors the temperaturebeing fed back from the temperature contact sensor 302. When thetemperature of the tray 62 is between the inputted high and lowtemperature presets for the alarm circuit 306, the alarm circuit 306 isactivated and closes a switch creating an electrical path through thealarm circuit 306. When the alarm circuit 306 is activated, a signal issent from the alarm circuit 306 to the PLC 230. If the PLC 230 does notreceive a signal from the alarm circuit 306, the PLC 230 sends a signalto activate an "error" lamp 246 indicating there is a temperatureproblem.

FIG. 11 is a perspective view of a second embodiment of a pre-prooftemperature controlling assembly 308. The second assembly 308 can beused in the off-press laminating apparatus 10, instead of and to performthe functions of the first assembly 8. Like the first assembly 8, thesecond pre-proof temperature controlling assembly 308 comprises a tray310 and means 312 for controlling the temperature of the stacked sheet,substrate and carrier plate on the tray 310 at about the thirdtemperature T3 while the stacked sheet, substrate and carrier plate arebeing fed to and then transported between the roller assemblies 40, 42.

The tray 310 has a top surface 314 and a bottom surface 316. The topsurface extends from the inlet 54 to about the nip 44 and functions likethe top surface 64 of the first assembly 8. The tray 310 includes ribsor fins 318 extending from the bottom surface 316 and extendingtransverse to the direction that the stacked sheet, substrate andcarrier plate are slid and transported. The tray 310 and fins 318 areformed as one piece, such as being cast or extruded. The tray 310 andfins 318 are aluminum. A hard, smooth tetrafluorethylene coating can beapplied to the top surface 314.

The controlling means 312 comprises an air blower 320, a manifold 322,and a flapper mechanism 324. The air blower 320 is preferably amotorized impeller. The manifold 322 comprises or defines a mainlongitudinal chamber 326 which extends transverse to the direction thatthe stacked sheet, substrate and carrier plate are moved. The fins 318extend in the main chamber 326. The manifold 322 further comprises ordefines a first inlet chamber 328 and a second inlet chamber 330. Thefirst inlet chamber 328 connects to a first end of the main chamber 326.The second inlet chamber 330 connects to a second end of the mainchamber 326. FIG. 12 is a cross sectional view through the first inletchamber 328.

Each inlet chamber 328, 330 includes an exterior port 331 positioned toreceive air at T3 from outside the housing 52. Each inlet chamber 328,330 also includes an interior port 334 positioned to receive air at T2from inside the housing 52. Preferably, the inlet chambers 328, 330 arepositioned below ends of the main chamber 326.

The manifold 322 further includes an outlet chamber 332 below and to themain chamber 326 connected by a passage 334. The passage 334 is spacedabout mid way from the ends of the main chamber 326. The outlet chamber332 has an exterior port 336 positioned to allow air to pass from theoutlet chamber 332 to outside the housing 52. The impeller 320 ispositioned in the outlet chamber 332 to draw air from the passage 334and to exhaust air through the exterior port 336 exterior to the housing52.

The flapper mechanism 324 is best shown in FIG. 13. The flappermechanism 324 comprises a first flapper 338 for controlling air flowthrough ports 331, 334 in inlet chamber 328, a second flapper 340 forcontrolling air flow through the ports 331, 334 in inlet chamber 328,330, and a shaft 342 connected to the flappers 338, 340. A motorassembly 344 is adapted to rotate a motor gear 346 on the motor shaft.The motor gear 346 connects to and drives a shaft gear 348 on the shaft342. Thus, when the motor assembly 344 is activated, it rotates themotor gear 346 which rotates the shaft gear 348 which rotates the shaft342 and the flappers 338, 340. The shaft 342 can be one piece or aplurality of shaft segments connected by couplers 343.

The flapper mechanism 324 includes means 350 for limiting rotation ofthe shaft 342 and flappers 338, 340 by deactivating the motor assembly344 when the flappers 338, 340 close the exterior ports 331 and when theflappers 338, 340 close the interior ports 334. The deactivating means350 may include a first limit switch 352, a second limit switch 354, afirst cam 356 on the shaft 342, a second cam 358 on the shaft 342. Thefirst and second cams 356, 358 have recesses 360. A first detent 362 onthe switch 352 extend into the recess 360 on the cam 356 deactivatingrotation in one direction such as when the flappers 338, 340 closeexterior ports 332. A second detent 364 on the other switch 354 extendsinto the recess 360 on the cam 358 deactivating rotation in the otherdirection such as when the flappers 338, 340 close interior ports 334.

The flapper mechanism 324 also includes means 366 for controlling theposition, i.e., rotation, of the shaft 342 and the flappers 338, 340.The controlling means 366 may include a potentiometer 368, a pot gear370 connected to a pot shaft, and a shaft gear 372 connected to the potgear 370. The potentiometer 368 provides an electrical signal such as toa computer or other control system, indicative of the position, i.e.,rotation, of the shaft 342. In response to this signal and other inputs,such as a signal representing the temperature of the tray 310 from atemperature sensor (not depicted), the computer or other control systemcan be programmed to control the motor assembly 344 to position theflappers 338, 340 to maintain the temperature of the tray 310 at apredetermined temperature.

Referring to FIG. 11, a sensor 374 can be provided at the leading edgeof the tray 310. The sensor can be connected to the computer to causethe flappers 338, 340 to close the exterior ports for a predeterminedtime period to increase the temperature of the tray 310 when a carrierplate initially passes onto the tray 310.

The laminator 12 can be like the laminator disclosed in U.S. Pat. No.5,075,722 and/or U.S. patent application Ser. No. 07/612,975 with theexceptions expressly noted in this specification. Suitable parts for thelaminator 12 including the lamination roller assemblies 40,42, therotating means 46, the heating means 48,50, and much of the electricalcontrol system 76 are disclosed in more detail in U.S. Pat. No.5,075,722 and U.S. patent application Ser. No. 07/612,975 which arehereby incorporated by reference.

A preferred carrier plate suitable for use in this invention isdescribed in co-pending U.S. patent application Ser. No. (Attorneydocket number IM-0827) and filed the same day as this specification.

The off-press apparatus 10 of the present invention can be used toperform an off-press method for laminating at least one color imagesheet to an image receiving substrate and then transferring the colorimage(s) from the receiving substrate to a transfer sheet to form aproof.

Specifically, referring to FIG. 14, a first precolored photosensitiveelement 410 comprising a first aqueously developable precoloredphotosensitive layer 412 on a first removable support 414 is exposed toactinic radiation through a first color separation transparency formingfirst image areas 416 and first non-image areas 418 in the firstaqueously developable precolored layer 412. The first precoloredphotosensitive element 410 may include a first adhesive layer 411between the first photosensitive layer 412 and the first removablesupport 414.

Next, the exposed first element 410' is processed to develop a firstcolor image by washing away the first non-image areas 418 with water.

Next, the first image bearing element 410' is stacked in registration onthe substrate 400 on the carrier plate 34 on the sheet preparation andfeed table 14 of the laminator 12. See FIGS. 3 and 14.

Next, the stacked first image bearing element 410', substrate 400 andcarrier plate 34 are slid along the tray 62 into the nip 44 between thepair of roller assemblies 40,42 heated to about the first temperature T1and which are parallel or substantially parallel.

Then, the first image bearing element 410' is laminated to theintermediate receiving substrate 400 by transporting the first imagebearing element 410' on the substrate 400 through the roller assemblies40,42 (heated by the heater elements 49,50) which are parallel orsubstantially parallel and which apply a first operating pressure orlinear force OLF1 on the first image bearing element 410' and thesubstrate 400. This first laminating step is illustrated in FIG. 14. Thesubstrate 400 may include a support layer 402 and an adhesive layer 404.FIG. 14 is a schematic illustration of laminating by applying pressureand heat through a nip 44 set to apply a first operating pressure orlinear force OLF1 by the first roller assembly 40 and the second rollerassembly 42 to sandwich the image bearing element 410' having onecolored image 416 together with the receiving substrate 400 having nocolored images.

During the sliding and laminating steps, the tray 62 and the first imagebearing element 410' substrate 400 and carrier plate 34 on the tray 62are cooled by the pre-proof temperature controlling assembly 8 to aboutthe third temperature T3 above room temperature and below the firsttemperature.

The first removable support 414 is then peeled and/or removed from thefirst image bearing element 410'. The first adhesive layer 411 canremain or substantially remain on the first image bearing element 419.The resulting laminate can be called a modified first image bearingelement 419. See FIG. 15.

Then, referring to FIG. 15, a transfer or display sheet 450, such as asheet of paper, can be stacked on the modified first image bearingelement 419 on the carrier plate 34 on the sheet preparation and feedtable 14 of the laminator 12.

Then, the stacked transfer sheet 450, modified first image bearingelement 419 and carrier plate 34 are slid along the tray 62 into the nip44 between the pair of roller assemblies 40,42 heated by the pre-prooftemperature controlling assembly 8 to about the temperature T1 and whichare parallel or substantially parallel.

Then, the stacked transfer sheet 450 is laminated to the modified firstimage bearing element 419 through the pair of heated rollers 40,42 setto apply a second operating pressure or linear force OLF2 on the firstimage bearing element 419 and the transfer sheet 450.

During the second sliding and second laminating steps, the tray 62 andthe transfer sheet 450, the modified first image bearing element 419,and carrier plate 34 on the tray 62 are cooled by the pre-prooftemperature controlling assembly 8 to about the temperature T3 aboveroom temperature and below the first temperature T1.

This can form a single color right reading proof. Alternatively, thesubstrate 402 can be peeled from the first image bearing element forminga single color right reading proof 490.

Alternatively, rather than laminating a transfer sheet 450 to the firstimage bearing element 419, a second image bearing element 420' can belaminated to the first image bearing element 419. See FIG. 16.

The second image bearing element 420' can be made by repeating theexposing step, the processing step, the stacking step, the sliding step,the laminating step, the cooling step, and the peeling step with (1) asecond precolored photosensitive element 420 comprising a secondaqueously developable precolored photosensitive layer 422 on a secondremovable support 424 instead of the first element, (2) a second colorseparation transparency instead of the first transparency, (3) in thestacking step, stacking the second image bearing element 420'substantially in register on the modified first image bearing element419, rather than on the substrate 400, and (4) in the laminating step,laminating the second image bearing element 420' substantially inregister on the modified first image bearing element 419, rather than onthe substrate 400. This second laminating step is illustrated in FIG.16.

Then the first exposing step, the first processing step, the firststacking step, the first sliding step, the first laminating step, thefirst cooling step, and the first peeling step can be repeated with (1)a third precolored photosensitive element 430 comprising a thirdaqueously developable precolored photosensitive layer 432 on a thirdremovable support 434 instead of the first element, (2) a third colorseparation transparency instead of the first transparency, (3) in thestacking step, stacking the third image bearing element 430' on themodified second image bearing element 429, rather than on the substrate400, and substantially in register with the modified first image bearingelement 419 and the modified second image bearing element 429, and (4)in the laminating step, laminating the third image bearing element 430'on the modified second image bearing element 429 substantially inregister with the modified first image bearing element 419. This thirdlaminating step is illustrated in FIG. 17.

Then the first exposing step, the first processing step, the firststacking step, the first sliding step, the first laminating step, thefirst cooling step, and the first peeling step can be repeated with (1)a fourth precolored photosensitive element 440 comprising a fourthaqueously developable precolored photosensitive layer 442 on a fourthremovable support 444 instead of the first element, (2) a fourth colorseparation transparency instead of the first transparency, (3) in thestacking step, stacking the fourth image bearing element 440' on themodified third image bearing element 439, rather than on the substrate400, and substantially in register with the modified first image bearingelement 419, the modified second image bearing element 429 and themodified third image bearing element 439, and (4) in the laminatingstep, laminating the fourth image bearing element 440' on the modifiedthird image bearing element 439 substantially in register with themodified first image bearing element 419. This fourth laminating step isillustrated in FIG. 18.

Suitable illustrative photosensitive elements 410,420,430,440 that canbe used in the present invention are disclosed in U.K. Patentpublication GB 2144867 B. For instance, the photosensitive elements410,420,430,440 can include from one side to the other a base layer, athin release layer or coating, a thin heat sealable adhesive layer orcoating and a photosensitive layer. When a release layer is included,preferably it is peeled off with the base layer as part of the removablesupports 414,424,434,444 in the peeling steps. In other words, inreference to FIGS. 14-19, each one of the support layers 414,424,434,444may comprise a plurality of layers including, for instance, a base layerand a thin release layer or coating. Suitable illustrative intermediatereceiving substrates 400 that can be used in the present invention aredisclosed in U.S. Pat. Nos. 4,482,625 and 4,766,053. For instance, theintermediate receiving substrates 400 can include from one side to theother a protective removable cover sheet, a thin heat curable adhesivelayer or coating, a thin release layer or coating, a thin first anchorlayer or coating, a polyester base layer, a thin second anchor layer orcoating, and a thin anti static layer or coating. When the receivingsubstrate 400 includes a release layer, preferably it is peeled off withits base layer in the last peeling step after the last laminating step.Thus, in reference to FIGS. 14-19, the support layer 402 may comprise aplurality of layers including, for instance, a thin release layer orcoating, a thin first anchor layer or coating, a polyester base layer, athin second anchor layer or coating, and a thin anti static layer orcoating.

The order of some of the steps is unimportant. For instance, all of thephotosensitive elements that are going to be laminated together can beexposed and then developed in any order prior to laminating them ontothe receiving substrate or prior laminate. For instance, all of thephotosensitive elements that are going to be laminated together can beexposed and developed prior to any of the laminating steps.Alternatively, after one photosensitive element is exposed anddeveloped, it can be laminated to the receiving substrate or priorlaminate before any other photosensitive element is exposed anddeveloped.

Finally, as illustrated in FIG. 19, a transfer or display sheet 450,such as a sheet of paper, is laminated to the fourth image bearingelement 449 through the pair of heated roller assemblies 40,42 set toapply a second operating pressure or linear force OLF2 on the multicolorbearing element 449, the transfer sheet 450 and the carrier plate 34sandwiching the first, second, third and fourth image bearing elements.This forms a four color right reading proof. Further, the support 402 ofthe substrate 400 can be peeled away and/or removed from the first imagebearing element forming a four color right reading proof 500. Theadhesive layer 404 originally forming part of the intermediate receivingsubstrate 404 can be (1) transferred to the transfer sheet 450 alongwith the multicolor image, (2) retained on the support 402 or (3)divided with part transferring to the transfer sheet 450 and partstaying on the support 402. FIG. 19 is a schematic illustration oflaminating by applying pressure and heat through the nip 44 set at asecond operating pressure or linear force OLF2 between the first rollerassembly 40 and the second roller assembly 42 to sandwich the receivingsubstrate 449 having four colored images together with a transfer sheet450 on a carrier plate 34.

Proper lamination occurs in specific and possibly different pressure (orlinear force) ranges, temperature ranges and transport speed rangesdepending on the materials being laminated together. However,preferably, the linear force applied by the lower roller assembly 42 onthe upper roller assembly 40 is at or about 5.35 pounds per linear inchfor each of the lamination steps except the last laminating step.Preferably, the linear force applied by the lower roller assembly 42 onthe upper roller assembly 40 is at or about 16 pounds per linear inchfor the last lamination step. Preferably, the transport speed is at orabout 400 millimeters per minute for each of the lamination steps. Underthese preferred conditions, when a four color proof is made by oneskilled in the art in accordance with the above described method of thepresent invention, the second, third and fourth images will typically bein register within about 60 microns with respect to the first image.

Before the last laminating step (illustrated in either FIG. 15 or 19)where the transfer sheet 450 is laminated to the multicolor imagebearing substrate 419 or 449, the first exposing step, the firstprocessing step, the first stacking step, the first sliding step, thefirst laminating step, the first cooling step, and the first peelingstep can be repeated one or more times with (1) an nth precoloredphotosensitive element comprising a nth aqueously developable precoloredphotosensitive layer on an nth removable support instead of the firstelement, (2) an nth color separation transparency instead of the firsttransparency, (3) in the stacking step, stacking the nth image bearingelement on the modified nth minus one image bearing element, rather thanon the substrate, and substantially in register with the modified firstimage bearing element, and (4) in the laminating step, laminating thenth image bearing element on the modified nth minus one image bearingelement and substantially in register with the modified first imagebearing element. Then in the last laminating step, the transfer sheet450 is laminated to the modified nth image bearing element.

Those skilled in the art, having the benefit of the teachings of thepresent invention as hereinabove set forth, can effect numerousmodifications thereto. These modifications are to be construed as beingencompassed within the scope of the present invention as set forth inthe appended claims.

What is claimed is:
 1. In an off-press apparatus for laminating an imagesheet to an image receiving substrate supported on a carrier plate, theapparatus comprising:a laminator comprising:a support frame having aright frame and a left frame; a first lamination roller assemblyrotatably mounted between the right frame and the left frame; a secondlamination roller assembly rotatably mounted between the right frame andthe left frame parallel or substantially parallel to the first rollerassembly forming a nip between the roller assemblies; means for rotatingthe first roller assembly and/or the second roller assembly; means forheating the first lamination roller assembly and the second laminationroller assembly to about a first temperature T1; and a housing forsubstantially enclosing the first lamination roller assembly, the secondlamination roller assembly, and the heating means, the housing having ahousing inlet and a housing outlet, the housing retaining heat generatedby the heating means within the housing generally at a secondtemperature T2 below the first temperature T1; a sheet preparation andfeed table having an end mounted to the laminator adjacent the housinginlet; and a sheet output receiving table having an end mounted to thelaminator adjacent the housing outlet; the improvement comprising: apre-proof temperature controlling assembly comprising:a tray with a topsurface and a bottom surface, the top surface extending from the housinginlet to about the nip such that when an image sheet is placed orstacked on an image receiving substrate on a carrier plate on the tableand the stacked sheet, substrate and carrier plate are slid along thetable into the housing inlet along the top surface of the tray into thenip between the first roller assembly and the second roller assembly,the roller assemblies will transport the stacked sheet, substrate andcarrier plate between the roller assemblies, laminate the sheet andsubstrate together and transport the laminated sheet and substrate andthe carrier plate out the housing outlet onto the sheet output receivingtable; and means for controlling the temperature of the stacked sheet,substrate and carrier plate on the tray at about a third temperature T3above room temperature T4 and below the second temperature T2 while thestacked sheet, substrate and carrier plate are being fed to and thentransported between the roller assemblies.
 2. In an off-press apparatusfor laminating an image sheet to an image receiving substrate supportedon a carrier plate, the apparatus comprising;a laminator comprising:asupport frame having a right frame and a left frame: a first laminationroller assembly rotatably mounted between the right frame and the leftframe; a second lamination roller assembly rotatably mounted between theright frame and the left frame parallel or substantially parallel to thefirst roller assembly forming a nip between the roller assemblies; meansfor rotating the first roller assembly and/or the second rollerassembly; means for heating the first lamination roller assembly and thesecond lamination roller assembly to about a first temperature T1; and ahousing for substantially enclosing the first lamination rollerassembly, the second lamination roller assembly, and the heating means,the housing having a housing inlet and a housing outlet, the housingretaining heat generated by the heating means within the housinggenerally at a second temperature T2 below the first temperature T1; asheet preparation and feed table having an end mounted to the laminateradjacent the housing inlet; and a sheet output receiving table having anend mounted to the laminater adjacent the housing outlet; theimprovement comprising: a pre-proof temperature controlling assemblycomprising:a tray with a top surface and a bottom surface, the topsurface extending from the housing inlet to about the nip such that whenan image sheet is placed or stacked on an image receiving substrate on acarrier plate on the table and the stacked sheet, substrate and carrierplate are slid along the table into the housing inlet along the topsurface of the tray into the nip between the first roller assembly andthe second roller assembly, the roller assemblies will transport thestacked sheet, substrate and carrier plate between the rollerassemblies, laminate the sheet and substrate together and transport thelaminated sheet and substrate and the carrier plate out the housingoutlet onto the sheet output receiving table; and means for controllingthe temperature of the stacked sheet, substrate and carrier plate on thetray at about a third temperature T3 above room temperature T4 and belowthe second temperature T2 while the stacked sheet, substrate and carrierplate are being fed to and then transported between the rollerassemblies, wherein the temperature controlling means comprises:a firstair blower having a first blower outlet and a first blower inletpositioned to receive air at about a fourth temperature below the thirdtemperature from outside the housing; a second air blower having asecond blower outlet and a second blower inlet positioned to receive airat about the second temperature from inside the housing; and a manifoldhaving at least a third outlet and connected to the first outlet and thesecond outlet for directing air from the first blower and the secondblower across the bottom surface of the tray and out the third outlet(s)to control the temperature of the tray and, thus, the stacked sheet,substrate and carrier plate slid on the tray.
 3. The off-press apparatusof claim 2, wherein the temperature controlling means furthercomprises:means in the manifold for directing air from the first outletaway from the second blower and for directing air from the second outletaway from the first blower.
 4. The off-press apparatus of claim 2,wherein the temperature controlling means further comprises:means forcontrolling the operation of the first blower and the second blower suchthat the first blower and the second blower operate alternately tomaintain the temperature of the tray substantially at the thirdtemperature.
 5. The off-press apparatus of claim 2, wherein the manifoldcomprisesa first duct having a first inlet, a second inlet and aplurality of outlets, the first duct first inlet connected to the firstblower outlet and the first duct second inlet connected to the secondblower outlet; a second duct and the bottom surface of the tray defininga plurality of chambers, each of the chambers having an inlet and anoutlet, one of the chamber inlets connected to each one of the pluralityof first duct outlets such that air blown through the chambers cool orheat the tray; and a plurality of third ducts, each one of the thirdducts having an inlet and an outlet, one of the third duct inletsconnected to each one of the chamber outlets, the third duct outletspositioned to exhaust air to the environment outside of the housing. 6.The off-press apparatus of claim 1, wherein the temperature controllingmeans further comprises:a pair of roller supports, one of the rollersupports mounted on each side of the tray transverse to the direction offeeding a stacked sheet, substrate and carrier plate to the nip, eachsupport having a plurality of bearing retaining slots; and a pluralityof non-lamination roller assemblies, each one of the non-laminationroller assemblies having a roller, shafts and bearings, the rollersextending above and transverse to the tray, the shafts extending outends of the rollers and the bearings rotatably supported on the shaftsand retained in the bearing retaining slots, such that when the stackedsheet, substrate and carrier plate are slid along the top surface of thetray towards the nip, the non-lamination roller assemblies apply aslight force on the stacked sheet, substrate and carrier platemaintaining it in contact with the tray.
 7. The off-press apparatus ofclaim 2, wherein the tray includes a plurality of thermally conductivefins extending into the manifold.
 8. The off-press apparatus of claim 1,wherein the tray is made of aluminum with a hard, smoothtetrafluoroethylene coating.
 9. The off-press apparatus of claim 1,wherein the first temperature T1 is about 100° C., the secondtemperature T2 is about 40°-45° C., the third temperature T3 istemperature is about 35° C., and the fourth temperature T4 is about 25°C.
 10. The off-press apparatus of claim 1, wherein the temperaturecontrolling means cools the temperature of the tray.
 11. In an off-pressapparatus for laminating an image sheet to an image receiving substratesupported on a carrier plate, the apparatus comprising:a laminatorcomprising:a support frame having a right frame and a left frame; afirst lamination roller assembly rotatably mounted between the rightframe and the left frame; a second lamination roller assembly rotatablymounted between the right frame and the left frame parallel orsubstantially parallel to the first roller assembly forming a nipbetween the roller assemblies: means for rotating the first rollerassembly and/or the second roller assembly; means for heating the firstlamination roller assembly and the second lamination roller assembly toabout a first temperature T1; and a housing for substantially enclosingthe first lamination roller assembly, the second lamination rollerassembly, and the heating means, the housing having a housing inlet anda housing outlet, the housing retaining heat generated by the heatingmeans within the housing generally at a second temperature T2 below thefirst temperature T1; a sheet preparation and feed table having an endmounted to the laminator adjacent the housing inlet; and a sheet outputreceiving table having an end mounted to the laminator adjacent thehousing outlet; the improvement comprising: a pre-proof temperaturecontrolling assembly comprising;a tray with a top surface and a bottomsurface, the top surface extending from the housing inlet to about thenip such that when an image sheet is placed or stacked on an imagereceiving substrate on a carrier plate on the table and the stackedsheet, substrate and carrier plate are slid along the table into thehousing inlet along the top surface of the tray into the nip between thefirst roller assembly and the second roller assembly, the rollerassemblies will transport the stacked sheet, substrate and carrier platebetween the roller assemblies, laminate the sheet and substrate togetherand transport the laminated sheet and substrate and the carrier plateout the housing outlet onto the sheet output receiving table; and meansfor controlling the temperature of the stacked sheet, substrate andcarrier plate on the tray at about a third temperature T3 above roomtemperature T4 and below the second temperature T2 while the stackedsheet, substrate and carrier plate are being fed to and then transportedbetween the roller assemblies, wherein the temperature controlling meanscomprises:a manifold comprising a main longitudinal chamber having afirst end and a second end, a first inlet chamber connected to the mainchamber first end, a second inlet chamber connected to the main chambersecond end, and an outlet chamber connected to the main chamber by apassage, the first and second inlet chambers having an exterior portpositioned to receive air at room temperature T4 from outside thehousing and an interior port positioned to receive air at the secondtemperature T2 from outside the housing, the outlet chamber having anexterior port positioned to allow air to pass from the outlet chamber tothe exterior of the housing; an air blower positioned in the outletchamber to draw air from the passage and exhaust the air out the outletchamber exterior port; and a flapper mechanism comprising a firstflapper for controlling air flow through the first inlet chamberexterior and interior ports, a second flapper for controlling air flowthrough the second inlet chamber exterior and interior ports a shaftconnected to the flappers, and means for rotating the shaft to controlair flow through the first and second inlet chamber exterior andinterior ports.